TW201408402A - Multi-component powder compaction molds and related methods - Google Patents

Abstract

A multi-component powder compaction mold configured for the production of cutting inserts is disclosed. A top section having a cavity wall forming a top cavity and a bottom section having a cavity wall forming a bottom cavity are stacked and aligned so that the top cavity and the bottom cavity collectively form a mold cavity. The mold cavity has a top cavity wall and a bottom cavity wall.

Description

Multi-component powder compacting die and related method

The present disclosure is directed to a mold for pressing a metallurgical powder to form a powder compact for use in making a cutting tool insert.

The modular cutting tool is a metal and alloy cutting tool of the type that uses an indexable cutting insert that is removably attached to a tool holder. Metal and alloy cutting inserts typically have a one-piece construction and one or more cutting edges at different corners or around the perimeter of the insert. The indexable cutting insert is mechanically fixed to the tool holder, but the blade can be adjusted and removed relative to the tool holder. The indexable cutting insert can be easily repositioned (eg, indexed) to provide a new cutting edge to the workpiece or can be replaced in the tool holder when, for example, the cutting edge is passivated or broken. In this manner, the indexable insert cutting tool is a modular cutting tool assembly that includes at least one cutting insert and a tool holder.

Cutting inserts include, for example, milling cutters, rotary cutters, drills, and the like. The cutting insert can be made of a hard material such as cemented carbide and ceramic. Such materials may be processed using powder metallurgy techniques such as blending, pressing, and sintering to make cutting inserts.

In a non-limiting embodiment, a multi-component powder compacting die configured to make a cutting insert is disclosed. The multi-component powder compacting die includes a top section and a bottom section. The top section includes a cavity wall that forms a top cavity in the top section. The bottom section includes a shape in the bottom section The wall of the cavity into the bottom cavity. The top section and the bottom section are stacked and aligned such that the top and bottom cavities collectively form a mold cavity including a top chamber wall and a bottom chamber wall.

In another non-limiting embodiment, a multi-component powder compacting die configured to make a cutting insert is disclosed. The multi-component powder compacting die includes an orthogonal top section, at least one angled intermediate section, and an orthogonal bottom section. The orthogonal top section includes orthogonal cavity walls that form a top cavity in the orthogonal top section. The at least one angled intermediate section includes an angled cavity wall forming at least one intermediate cavity in the angled intermediate section. The orthogonal bottom section includes orthogonal cavity walls that form a bottom cavity in the orthogonal bottom section. The orthogonal top section, the at least one angled intermediate section, and the orthogonal bottom section are stacked and aligned such that the top cavity, the at least one intermediate cavity, and the bottom cavity together form an orthogonal top cavity wall, at least one angled intermediate cavity wall And a cavity of the orthogonal bottom cavity wall (which forms a horizontal corner intersection in the cavity).

In another non-limiting embodiment, a process for making a multi-component powder compaction mold is disclosed. The workpiece is cut using a linear material cutting technique to form an orthogonal top section that includes orthogonal cavity walls that form orthogonal top cavities in the top section. The workpiece is cut using a linear material cutting technique to form an angled intermediate section that includes angled cavity walls that form at least one angled intermediate cavity in the angled intermediate section. The workpiece is cut using a linear material cutting technique to form an orthogonal bottom section that includes orthogonal cavity walls that form orthogonal bottom cavities in the bottom section. The orthogonal top section, the angled intermediate section, and the orthogonal bottom section are stacked and aligned such that the top cavity, the at least one intermediate cavity, and the bottom cavity together form an orthogonal top cavity wall, an angled intermediate cavity wall, and an orthogonal A cavity of the bottom chamber wall (which forms a horizontal corner intersection in the cavity). The orthogonal top section, the angled intermediate section, and the orthogonal bottom section are joined to form a multi-element powder compaction mold.

It is to be understood that the invention disclosed and described herein is not limited to the embodiments of the invention.

10‧‧‧EDM electrode

12‧‧‧ horizontal corner intersection

14‧‧‧Face intersection / round horizontal corner

16‧‧‧ corner intersection

20‧‧‧Workpiece

20'‧‧‧Single powder compaction mould

21‧‧‧ cavity

22‧‧‧Circular horizontal corner intersection

23‧‧‧Upper wall

23'‧‧‧ upper wall

24‧‧‧Circular horizontal corner intersection

24'‧‧‧ sharp horizontal corners

25‧‧‧Intermediate cavity wall

25'‧‧‧Intermediate cavity wall

26‧‧‧Circular horizontal corner intersection

26'‧‧‧ sharp horizontal corners

27‧‧‧ lower wall

27'‧‧‧ lower wall

30‧‧‧EDM electrode

36‧‧‧ horizontal corner intersection

40‧‧‧Workpiece

40'‧‧‧Single powder compaction mould

41‧‧‧Preformed cavity

41'‧‧‧ cavity

43‧‧‧ upper wall

45‧‧‧Intermediate cavity wall

46‧‧‧Circular horizontal corners

47‧‧‧ cavity wall

50‧‧‧middle section

51‧‧‧ top surface

52‧‧‧ Alignment holes

53‧‧‧ bottom surface

55‧‧‧An angled cavity wall

58‧‧‧Parts

59‧‧‧Basic square cavity

60‧‧‧Linear electrode

61‧‧‧ pulley

70‧‧‧Top or bottom section

71‧‧‧ top surface

72‧‧‧ Alignment holes

73‧‧‧ bottom surface

75‧‧‧Orthogonal cavity wall

78‧‧‧Parts

80‧‧‧Linear electrode

81‧‧‧ pulley

100‧‧‧Multi-component powder compaction mould

105‧‧‧ Alignment holes

105a‧‧‧ Alignment hole

105b‧‧‧ Alignment holes

105c‧‧‧ Alignment hole

110‧‧‧ cavity

110a‧‧‧ cavity/top cavity

110b‧‧‧ cavity/intermediate cavity

110c‧‧‧ cavity/bottom cavity

130‧‧‧Top section

131‧‧‧ top surface

133‧‧‧ bottom surface

135‧‧‧ cavity wall

150‧‧‧middle section

151‧‧‧ top surface

153‧‧‧ bottom surface

155‧‧‧ cavity wall

170‧‧‧ bottom section

171‧‧‧ top surface

173‧‧‧ bottom surface

175‧‧‧ cavity wall

200‧‧‧Multi-component powder compaction mould

210‧‧‧Circular cavity

230‧‧‧Orthogonal top section

235‧‧‧Orthogonal cavity wall

250‧‧‧Angle intermediate section

255‧‧‧An angled cavity wall

270‧‧‧Orthogonal bottom section

275‧‧‧Orthogonal cavity wall

300‧‧‧Multi-component powder compaction mould

305‧‧‧ Aligned holes

310‧‧‧ cavity

330‧‧‧Orthogonal top section

350‧‧‧Angle intermediate section

370‧‧‧Orthogonal bottom section

390‧‧‧Contouring the bottom and top surfaces

400‧‧‧Multi-component powder compaction mould

410‧‧‧ cavity

430‧‧‧Orthogonal top section

435‧‧‧Orthogonal cavity

450a‧‧‧Upper angle intermediate section

450b‧‧‧ Lower angle intermediate section

455a‧‧‧Upper angled wall

455b‧‧‧An angled cavity wall

470‧‧‧Orthogonal bottom section

475‧‧‧Orthogonal cavity wall

500‧‧‧Multi-component powder compaction mould

510‧‧‧ cavity

530‧‧‧ Angled top section

535‧‧‧An angled cavity wall

570‧‧‧Orthogonal bottom section

575‧‧‧Orthogonal cavity wall

600‧‧‧Multi-component powder compaction mould

610‧‧‧ cavity

630‧‧‧Orthogonal top section

650‧‧‧Angle intermediate section

670‧‧‧Orthogonal bottom section

700‧‧‧Multi-component powder compaction mould

710‧‧‧Suppressed punch

711‧‧‧ arrow

715‧‧‧ core assembly

720‧‧‧ Pressing punch

721‧‧‧ arrow

750‧‧‧metallurgical powder

800‧‧‧Cutting blade powder compact

800'‧‧‧Cutting blade powder compact

810‧‧‧through hole

810'‧‧‧through hole

900‧‧‧Multi-component powder compaction mould

910‧‧‧Upper punch

915‧‧‧ core assembly

920‧‧‧ Pressing punch

1000‧‧‧Cutting blade powder compact

1000'‧‧‧Cutting blade powder compact

The non-limiting and non-exhaustive detailed embodiments disclosed and described in this specification are different. The characteristics of the engraving can be better understood with reference to the accompanying drawings, wherein: FIG. 1A to FIG. 1F are schematic diagrams showing the fabrication of a monolithic powder compacting mold using a die-discharge machining; FIG. 2A and FIG. FIG. 3A to FIG. 3E are schematic diagrams showing the fabrication of a monolithic powder compacting die using a die-cutting electrical discharge; FIG. 4A to FIG. Schematic diagram of the fabrication of an angled intermediate section of a multi-component powder compaction die using wire-cut electrical discharge machining; FIGS. 5A and 5B illustrate the orthogonal top section of a multi-component powder compaction die using wire-cut electrical discharge machining Figure 6A is a perspective view of a multi-component powder compaction mold comprising orthogonal top sections, angled intermediate sections and orthogonal bottom sections, wherein the mold cavity comprises a substantially square perimeter shape; Figure 6B is a Figure 6A FIG. 6C is a side cross-sectional view of the multi-component powder compacting mold shown in FIGS. 6A and 6B; FIG. 6D is a cross-sectional view showing the multi-component powder compacting mold shown in FIG. 6A to FIG. Schematic diagram of the orientation of the compaction die of the powder relative to the pressing axis and the pressing plane of the die Figure 7 is a perspective view of the multi-component powder compacting mold shown in Figures 6A, 6B and 6C; Figure 8 is a multi-component powder compacting mold shown in Figures 6A, 6B and 6C and Figure 7. FIG. 9A is a perspective view of a multi-component powder compacting mold including an orthogonal top section, an angled intermediate section, and an orthogonal bottom section, wherein the mold cavity includes a substantially circular peripheral shape; 9B is a cross-sectional perspective view of the multi-component powder compacting mold shown in FIG. 9A; FIG. 10A is a perspective view of a multi-component powder compacting mold including an orthogonal top section, an angled intermediate section, and an orthogonal bottom section, wherein The mold cavity includes a substantially square peripheral shape, and a top surface of the middle section and a bottom surface of the top section are contoured to each other; FIG. 10B is a cross-sectional perspective view of the multi-component powder compacting mold shown in FIG. 10A; Figure 11A is a perspective view of a multi-element powder compaction mold comprising orthogonal top sections, two angled intermediate sections and orthogonal bottom sections, wherein the mold cavity comprises a generally square perimeter shape; Figure 11B is shown in Figure 11A. FIG. 11C is a side cross-sectional view of the multi-component powder compacting mold shown in FIGS. 11A and 11B; FIG. 12A includes an angled top section and an orthogonal bottom section. A perspective view of a multi-component powder compacting mold in which a cavity includes a substantially square peripheral shape; FIG. 12B is a cross-sectional perspective view of the multi-component powder compacting mold shown in FIG. 12A; and FIG. 12C is a multi-component shown in FIGS. 12A and 12B. A side cross-sectional view of a powder compacting die; FIG. 13 is a perspective view of a multi-component powder compacting die including an orthogonal top section, an angled intermediate section, and an orthogonal bottom section, wherein the mold includes a plurality of mold cavities Wherein the cavity comprises a substantially square perimeter shape; and FIGS. 14A-14C illustrate the use of a multi-component powder compaction die comprising an orthogonal top section, an angled intermediate section and an orthogonal bottom section to produce a cutting insert powder compact. Schematic; Figure 15A is based on Figure 14 A perspective view of a substantially square cutting insert powder compact produced by the process shown in FIG. 14C; FIG. 15B is a perspective view of a substantially circular cutting insert powder compact produced according to the process illustrated in FIGS. 14A to 14C; FIG. A schematic diagram of making a cutting insert powder compact using a multi-component powder compacting mold comprising an orthogonal top section, two angled intermediate sections and an orthogonal bottom section; FIG. 17A is a process according to FIG. A perspective view of a substantially square cutting insert powder compact produced; and FIG. 17B is a perspective view of a substantially circular cutting insert powder compact produced in accordance with the process illustrated in FIG. 16; the reader is considering different non-limiting and non-limiting aspects in accordance with the present specification. The above details and others will be apparent from the following detailed description of the embodiments.

Various embodiments are described and illustrated in this specification to provide a general understanding of the structure, function, operation, manufacture and use of the disclosed multi-component powder compaction mold. Should understand this statement The various embodiments described and illustrated in the specification are non-limiting and not exhaustive. Therefore, the present invention is not necessarily limited to the description of the various non-limiting and non-exhaustive embodiments disclosed herein. Features and characteristics shown and/or described in connection with the various embodiments may be combined with features and characteristics of other embodiments. Such modifications and variations are intended to be included within the scope of the present specification. Accordingly, the scope of the patent application may be modified to cite any feature or characteristic that is explicitly or in the nature of the description or otherwise. In addition, the Applicant reserves the right to modify the scope of the patent application to abandon the rights or features that may exist in the prior art. Therefore, any such modifications are in accordance with 35 U.S.C. § 112, paragraph 1 and 35 U.S.C. § 132(a). The various embodiments shown and described herein may comprise, consist of, or consist essentially of the features and characteristics as described herein.

The entire disclosure of any patents, publications, or other disclosures herein is hereby incorporated by reference in its entirety in the specification, unless Other disclosures reveal material conflicts. Thus, and to the extent required, the explicit disclosure as set forth in this specification is inferr Any material or portion thereof that is incorporated herein by reference to the present disclosure, which is inconsistent with the existing definitions, descriptions, or other disclosures disclosed herein, is only incorporated in the context of the incorporation of the material and the present disclosure. Applicants reserve the right to modify this specification to explicitly recite any subject matter or portions thereof incorporated herein by reference.

The syllabuses "a", "a", "an" and "the" are used to include "at least one" or "one or more". Therefore, articles are used in this specification to refer to one or more than one (ie, "at least one") grammatical object. For example, a "component" refers to one or more components and thus may be considered in excess of one component and may be utilized or used in embodiments of the embodiments. In addition, the use of singular nouns includes the plural and the use of plural nouns includes the singular unless the context requires otherwise.

The cutting insert can be manufactured using powder metallurgy techniques such as blending, pressing and sintering of powdered metal. For example, a cemented carbide cutting insert (eg, which includes tungsten carbide hard particles and a cobalt-based binder) can be made by blending a metal carbide powder and a metal binder powder, and pressing the blend in a mold. The metallurgical powder forms a powder compact of the shape of the cutting insert, and the powder compact is sintered to compact the composite into a cemented carbide cutting insert. In such processes, pressing the metallurgical powder into a powder compact can be a near net forming operation in which the geometry of the cavity and the press punch must closely match the final geometry of the fabricated cutting insert. Therefore, it is important that the powder compacting die used to make the cutting insert has accurate and precise geometric and structural features that can be transferred from the mold cavity to the pressed powder compact and by any structural or geometrical deviations or inconsistencies. Sintered cutting inserts.

The manufacture of powder compacting dies for making cutting inserts is therefore important given the importance of the geometry and structural accuracy and precision of the mold cavity. One method of making a powder compaction die involves the use of EDM, also referred to as a die EDM, a plunger EDM, or a punch EDM.

The electrical discharge machining operates on the principle of spark erosion, in which the workpiece material is corroded by the discharge between the electrode and the workpiece. In EDM operation, the power supply provides current such that a large voltage is applied between the electrode and the workpiece held in opposite polarity. The electrodes and the workpiece are brought in close proximity, but separated by a small gap that fills the dielectric fluid. The dielectric fluid acts as an insulating material that allows for the accumulation of opposite polarity charges on the electrodes and the surface of the workpiece, respectively. When a sufficient voltage appears between the electrode and the workpiece, the dielectric fluid decomposes and ionizes, thereby forming a plasma passage through the gap between the electrode and the workpiece. The accumulated charge rapidly discharges through the ionized plasma channel, creating an electrical spark between the electrode and the workpiece and generating a large amount of heat that melts and vaporizes the material that makes up the workpiece. In this way, spark erosion is used to machine the workpiece while maintaining a gap between the electrode and the workpiece that is needed to prevent shorting. Electrical discharge machining is described in more detail by Elman C. Jameson, Electrical Discharge Machining , Society of Manufacturing Engineers (SME), 2001, which is incorporated herein by reference.

EDM technology includes die-cut EDM, wire-cut EDM (also known as wire-cut EDM and wire cutting) and small hole EDM punching. Engraving EDM involves the use of preformed electrodes to form a blind or perforated cavity in a workpiece. The EDM electrode is preformed to have a geometry and size corresponding to the shape of the cavity to be machined into the workpiece. In operation, a computer numerical control (CNC) system advances the die electrode into the workpiece, maintaining the required clearance and circulating the electrical power according to the duty cycle. The circulating electrical power creates an electrical spark along the surface forming the electrode during the duty cycle on time, which corrodes the surface of the workpiece accordingly, thereby transferring the geometry of the electrode into the workpiece. The flowing dielectric fluid purges the corroded material from the gap between the electrode and the workpiece during the off time of the duty cycle.

Both the electrode and the workpiece in the EDM must be electrically conductive to create the voltage required to cause dielectric breakdown, ionization, sparking, and corrosion. Workpieces including any conductive metal, alloy, cemented carbide or other material can be processed using EDM. The EDM electrode is roughly made of graphite, tungsten, copper tungsten or tungsten carbide. Regardless of the build material, all EDM electrodes exhibited substantial corrosion during EDM operation. The maximum amount of electrode corrosion occurs at the corner intersections of the electrode surfaces because the spark density is large due to the large workpiece area near the corner intersection. Corrosion of the EDM electrode of the stencil changes the geometry of the electrode, which in turn causes deviations and inconsistencies in the geometry transferred into the cavity machined in the workpiece.

Corrosion of the EDM electrode of the stencil may be particularly problematic in the manufacture of powder compacting dies for making cutting inserts due to structural or geometrical deviations and inconsistencies transferred from the etched electrode to the mold cavity followed by pressing of the pressed powder The block is transferred to a sintered cutting insert. The structural or geometrical deviation of the cavity may also inhibit the action of the pressing punch from effectively entering the cavity and compacting the metallurgical powder. This can be particularly problematic because pressing the metallurgical powder into a powder compact can be a near net forming operation in which the geometry of the cavity and die punch must closely match the final geometry of the fabricated cutting insert.

For example, FIGS. 1A-1F illustrate the fabrication of a monolithic powder compacting die using a stencil EDM. As used herein, the term "monolithic" refers to assembly with multiple discrete components. Made or formed from a single piece of material. The stenciled EDM electrode 10 includes a geometry that will be formed in the workpiece 20 to create a mold cavity for the monolithic compaction mold used to make the cutting insert. As the EDM electrode 10 travels into the workpiece 20, spark erosion between the surface of the electrode 10 and the surface of the workpiece 20 etches the workpiece and transfers the geometry of the electrode 10 into the workpiece 20. The stenciled EDM electrode 10 is also etched during spark erosion, particularly at the horizontal corner intersection 12 of the electrode 10, wherein the corners are rounded, thereby forming a circular horizontal corner intersection 22 in the workpiece 20.

Referring to FIGS. 1C and 1D, when the EDM electrode 10 is further advanced into the workpiece 20 to form a correspondingly formed cavity, the electrode 10 continues to erode on the horizontal corner intersection 12 (making a circular horizontal corner intersection 22 And also etched on the horizontal corner intersection 14 (making a circular horizontal corner 14) which is transferred to the workpiece by a spark erosion process, thereby forming a circular horizontal corner intersection 24. Referring to FIG. 1E, as the electrode 10 is fully advanced into the workpiece 20, corrosion on the corner intersections 14 and 16 of the electrode 10 has created circular horizontal corner intersections 24 and 26 in the workpiece 20.

FIG. 1F illustrates a monolithic powder compacting die 20' fabricated using a die EDM as shown in FIGS. 1A-1E. The monolithic compaction mold 20' includes a mold cavity 21 that includes an upper chamber wall 23, an intermediate chamber wall 25, and a lower chamber wall 27. The cavity walls 23 and 27 will allow the pressing punch to enter the die 20' and the cavity wall 25 will form the peripheral surface of the cutting insert sintered by the compacted compact of the die 20'. The upper chamber wall 23 is separated from the intermediate chamber wall 25 by a circular horizontal corner 26, as shown in Fig. 2A, which is an enlarged view of the circular horizontal corner shown by circle A in Fig. 1F. The lower chamber wall 27 is separated from the intermediate chamber wall 25 by a circular horizontal corner 26, as shown in Fig. 2B, which is an enlarged view of the circular horizontal corner shown by circle B in Fig. 1F.

The corners of the EDM electrode 10 for forming the cavity 21 are corroded to form circular horizontal corners 24 and 26. Referring to Figure 2A, in the absence of corner erosion of the electrodes, the mold cavity 21 will include sharp horizontal corners 26' formed on the intersection of the upper chamber wall 23' and the intermediate chamber wall 25'. Referring to FIG. 2B, in the absence of edge etching of the electrode, the cavity 21 will be formed in the lower cavity. A sharp horizontal corner 24' of the intersection of the wall 27' and the intermediate cavity wall 25'.

3A-3D illustrate the fabrication of a monolithic compaction mold using a modified EDM process. The diced EDM electrode 30 portion includes a geometry that will be formed in the workpiece 40 to create a mold cavity for a monolithic compaction mold for making a cutting insert. The workpiece 40 includes a preformed cavity 41 that spans the thickness of the workpiece. The preformed cavity 41 includes a peripheral shape of a cavity that will be formed in the workpiece 40 and can be pre-cut into a workpiece using linear material cutting techniques such as, for example, wire cut EDM, laser cutting, or water jet cutting.

The stenciled EDM electrode 30 is centered on the pre-formed cavity 41. As the EDM electrode 30 travels into the workpiece 40, spark erosion between the surface of the electrode 30 and the surface of the workpiece 40 etches the workpiece and transfers the geometry of the electrode 30 into the workpiece 40. The stenciled EDM electrode 30 is also etched during spark erosion, particularly at the horizontal corner intersection 36 of the electrode 30, wherein the corners are rounded thereby creating a circular horizontal corner intersection 46 in the workpiece 40. Referring to FIG. 3D, when the electrode 30 is fully advanced into the workpiece 40, corrosion on the corner intersection 36 of the electrode 30 has created a circular horizontal corner intersection 46 in the workpiece 40.

FIG. 3E illustrates a monolithic powder compacting die 40' fabricated using a die EDM as shown in FIGS. 3A-3D. The monolithic compaction mold 40' includes a mold cavity 41' that includes an upper chamber wall 43, an intermediate chamber wall 45, and a lower chamber wall 47. The chamber walls 43 and 47 will allow the pressing punch to enter the die 40' and the cavity wall 45 will form the peripheral surface of the cutting insert that is sintered by the compacted powder compacted in the die 40'. The upper chamber wall 43 is separated from the intermediate chamber wall 45 by a circular horizontal corner 46. The circular horizontal corner 46 is similar to the circular horizontal corner 26 shown in detail in Figure 2A. The corners of the EDM electrode 30 for forming the cavity 41' are corroded to form a circular horizontal corner 46.

The circular horizontal corners in the cavity of the monolithic compaction die made using the EDM can limit the use of the die in the production of pressed and sintered cutting inserts because the rounded corners prevent the pressing of the punch The mold is effectively brought into the desired position to achieve efficient compaction of the metallurgical powder. In addition, since the mold is a two-step process, it includes: (1) shaping the EDM electrode of the mold; and (2) conducting the EDM with the electrode; therefore, any error in the electrode fabrication (example) For example, deviations or inconsistencies in the structure, geometry or dimensions of the electrodes will be transferred to the mold cavity, which may be due to any inherent errors in the inherent corrosion of the electrodes themselves.

In order to solve such problems, the inventors tested different material configurations used as the EDM electrodes of the stencil and different material configurations for use as powder compacting dies. In addition, different EDM parameters, such as, for example, applied voltage and duty cycle are evaluated during the fabrication of the powder compacting mold using the EDM. A number of diced EDM electrodes have also been investigated for roughing, semi-finishing and finishing of the cavity to final dimensions and geometries. However, the use of different materials of construction, multiple electrodes, and optimized EDM parameters are not sufficient to reduce or eliminate variations in the shape of the cavity in a monolithic compaction die made using a stencil EDM.

The different non-limiting embodiments described in this specification address the problems associated with the use of a single-piece powder compaction die comprising a plurality of sections, the multi-component powder compaction die comprising a plurality of sections, by providing a multi-component powder compaction die When assembled, the plurality of segments form a cavity having a sharp horizontal corner intersection and having no rounding, inconsistency and shape deviation inherent to the single-piece powder compacting die produced by using the EDM. In various non-limiting embodiments, various sections of the multi-component powder compaction die can be fabricated individually using linear material cutting techniques, such as, for example, wire-cut EDM, laser cutting, or water jet cutting.

As with the EDM, the wire-cut EDM operation uses a spark erosion process between the electrode and the workpiece to process a conductive material such as, for example, a metal, an alloy, and a cemented carbide. However, instead of pre-forming the EDM electrodes that travel into the workpiece, the wire-cut EDM uses a continuous and linear feed through the thickness of the workpiece and laterally through the width and length dimensions of the workpiece to cut the wire-shaped electrodes that make up the material of the workpiece. In operation, a computer numerical control (CNC) system continuously feeds the wire electrodes through the thickness of the workpiece and the laterally translated linear electrodes through the width and length dimensions of the workpiece, maintaining the desired electrode-to-work gap and cycling the electrical power according to the duty cycle. The circulating electrical power generates an electrical spark between the wire electrode and the workpiece material surrounding the wire electrode during the duty cycle on time, which corrodes the workpiece material accordingly, thereby depending on the controlled lateral movement of the wire electrode in lateral width and length Cutting the workpiece in size. Dielectric current at the turn-off time of the duty cycle The corroded material is rinsed away from the gap between the wire electrode and the workpiece during the process.

Wire-cut EDM can be considered as a linear material cutting technique in the sense of linear cutting through the thickness of the workpiece. However, it should be understood that wire cut EDM is not limited to linear cuts that pass through the lateral dimensions (i.e., width and length) of the workpiece, and wire cut EDM can be used to make bow cuts, linear cuts, and combinations thereof, in lateral dimensions. Similarly, laser cutting and water jet cutting are considered as linear material cutting techniques because the laser beam and water jet used to cut the workpiece are made through a linear slit of the thickness dimension of the workpiece but can be fabricated in lateral dimensions. An arcuate incision, a linear incision, or a combination thereof.

The linear electrodes in the wire-cut EDM operation are also corroded due to the spark erosion process. However, unlike the EDM operation, in the in-line EDM operation, the new wire electrode is continuously fed through the workpiece and thus any defects or inconsistencies in the wire electrode due to the spark erosion process are not transferred to the workpiece. Therefore, the multi-component powder compacting die produced by the wire-cut EDM operation does not exhibit the horizontal corner rounding, inconsistency, and shape deviation inherent in the monolithic compaction die produced using the die-cut EDM.

4A-4D illustrate the fabrication of the intermediate section 50 of a multi-component powder compaction die using wire cut EDM. The intermediate section 50 includes a top surface 51 and a bottom surface 53. The linear electrode 60 is continuously and linearly fed through the thickness of the workpiece and translated through the lateral dimension of the workpiece (ie, along the top surface 51 and the bottom surface 53) in a combination of linear and arcuate lateral paths to cut out Portion 58 and forming an angled cavity wall 55. The wire electrode 60 is fed through the workpiece 50 by a pulley 61. In this manner, the wire-cut EDM operation cuts the substantially square cavity 59 through the thickness of the workpiece, thereby making the intermediate section 50 of the multi-component powder compaction die. The intermediate section 50 of the multi-component powder compaction die includes alignment holes 52 that can be cut out using wire-cut EDM or any other suitable machining operation and can function to ensure intermediate section 50 and top section and bottom section Alignment (not shown).

5A and 5B illustrate the fabrication of a top or bottom section 70 of a multi-component powder compacting die using wire cut EDM. The top or bottom section 70 includes a top surface 71 and a bottom surface 73. The linear electrode 80 is continuously and linearly fed through the thickness of the workpiece and translated through the lateral dimension of the workpiece (ie, along the top surface 71 and bottom surface 73) in a combination of linear and arcuate lateral paths to cut out Portion 78 and form an orthogonal cavity wall 75. The linear electrode 80 is fed through the workpiece 70 by a pulley 81. In this manner, the wire-cut EDM manipulates the thickness of the workpiece through a substantially square cavity (in the space occupied by the cut-out portion 78), thereby creating a top or bottom section 70 of the multi-component powder compaction die. The top or bottom section 70 of the multi-component powder compaction mold includes alignment holes 72 that can be cut and acted using wire-cut EDM or any other suitable machining operation to ensure top or bottom section 70 and intermediate section Alignment.

6A-6C illustrate a multi-component powder compacting die 100 including a top section 130, a middle section 150, and a bottom section 170. The mold 100 includes a mold cavity 110 formed by respective cavities 110a, 110b, and 110c of the top section 130, the intermediate section 150, and the bottom section 170 (see FIGS. 7 and 8). When assembled together, the cavity 110a of the top section 130, the cavity 110b of the intermediate section 150, and the cavity 110c of the bottom section 170 form the cavity 110 of the mold 100. The cavity 110 has a sharp horizontal corner intersection between the orthogonal cavity wall 135 (of the top section 130) and the angled cavity wall 155 (of the intermediate section 150). The mold cavity 110 also has a sharp horizontal corner intersection between the angled cavity wall 155 (of the intermediate section 150) and the orthogonal cavity wall 175 (of the bottom section 170). The mold 100 has no rounding, inconsistency, and shape deviation inherent in the single-piece powder compacting die produced by using the EDM.

The use of the terms "orthogonal" and "angled" with respect to the wall of the segment refers to the orientation of the wall of the cavity relative to the plane of compression of the die. Next, the "pressing plane" is perpendicular to the plane of the pressing axis of the mold. For example, referring to FIG. 6D, top section 130 and bottom section 170 respectively include cavity walls 135 and 175 that are substantially perpendicular (ie, orthogonal) to the pressing plane (P) of mold 100. The intermediate section 150 includes a cavity wall 155 that forms a substantially non-perpendicular angle ([theta]) with respect to the pressing plane (P) of the die 100. The pressing plane (P) is perpendicular to the pressing axis (X), which is defined as a pressing punch (not shown) that travels as it enters the multi-component powder compacting die 100 and compresses the metallurgical powder into a powder compact (not shown). direction. In this way, the top section 130 and the bottom section 170 It can be referred to as an orthogonal segment and the intermediate segment 150 can be referred to as an angled segment. Likewise, the top chamber 110a and the bottom chamber 110c may be referred to as orthogonal chambers and the intermediate chamber 110b may be referred to as an angled chamber.

The pressing plane is perpendicular to the pressing axis and passes through the plane of the section of the specified multi-component powder compacting die. The orthogonal cavity walls (of the orthogonal cavity/orthogonal segments) will be perpendicular to the pressing plane and parallel to the pressing axis. The angled cavity walls (of angled cavities/angled segments) will form a substantially non-perpendicular angle with respect to the pressing plane and will form a complementary angle with respect to the pressing axis (ie, the sum of the angles is 90°).

In various non-limiting embodiments, the multi-component powder compacting die can include sections having a top and/or bottom surface that is generally parallel to the pressing plane of the die (and generally perpendicular to the die axis of the die). For example, referring to FIGS. 7 and 8, the top section 130 and the bottom section 170 respectively include chamber walls 135 and 175 that are substantially perpendicular to the top surfaces (131 and 171) of the top section 130 and the bottom section 170. And the bottom surface (133 and 173). The intermediate section 150 includes a cavity wall 155 that forms a substantially non-perpendicular angle with respect to the top surface 151 and the bottom surface 153 of the intermediate section 150.

In various non-limiting embodiments, the multi-component powder compacting die can include sections having a top and/or bottom surface that is non-parallel to the pressing plane of the mold (and non-perpendicular to the pressing axis of the mold). For example, a multi-component powder compaction die can include sections having a contoured top and/or a contoured bottom surface (see Figures 10A and 10B); and in other non-limiting embodiments, multi-component powder compaction The mold may comprise a section having a flat top and/or bottom surface, wherein the flat surface forms a constant or varying angle with respect to the pressing plane and/or the pressing axis of the mold. In such embodiments, the different segments may still be referred to as depending on whether the walls of the segments are substantially perpendicular (i.e., orthogonal) to the pressing plane of the die 100 or form a substantially non-perpendicular angle relative to the pressing plane of the die. Orthogonal section or Angled section.

Referring to Figures 6A-8, the top section 130, the intermediate section 150, and the bottom section 170 can use linear material cutting techniques (for example, such as wire cut EDM, laser cutting, or water jetting) Flow cutting) is produced by cutting out the cavities 110a, 110b, and 110c, respectively. Likewise, linear material cutting techniques (such as wire cut EDM, laser cutting or water jet cutting) or any other suitable processing technique can be used to cut out alignments in top section 130, intermediate section 150, and bottom section 170, respectively. Holes 105a, 105b and 105c. Referring to Figures 7 and 8, the respective alignment apertures 105a, 105b, and 105c are configured to align the respective segments such that the respective cavity walls 135, 155, and 175 intersect to form a corner that is not problematic or otherwise Sharp horizontal corners of inconsistencies in the problem (see Figure 6C). The bottom surface 133 of the top section 130 is configured to match the top surface 151 of the intermediate section 150 when in an assembled (ie, stacked and aligned) configuration (as shown in Figures 6A-6C). Likewise, the bottom surface 153 of the intermediate section 150 is configured to match the top surface 171 of the bottom section 170 when in the assembled configuration.

When in the assembled configuration (ie, stacked and aligned as shown in Figures 6A-6C), the alignment holes 105 (including the respective alignment holes aligned along lines A and B as shown in Figures 7 and 8) 105a, 105b, and 105c) travel from the top surface 131 of the top section 130 through the die (including all stacked sections) to the bottom surface 173 of the bottom section 170.

The multi-component powder compacting die according to various non-limiting embodiments can include a mold cavity having any peripheral shape formed by a cavity wall including a plurality of die segments of the die. For example, Figures 6A-6C, 7 and 7 illustrate a non-limiting embodiment comprising a generally square mold cavity that produces a substantially square metallurgical powder compact that can be sintered to make a substantially square cutting insert. The term "substantially" used relative to the shape of the periphery of the cavity indicates that the shape can be formed by a vertical fillet (as shown in Figures 6A, 6B, and 7) that includes transitions between intersecting surfaces rather than intersecting vertices. Deviate from the specified geometry.

The multi-component powder compacting die according to various non-limiting embodiments may include a mold cavity including peripheral shapes such as, for example, a circle, a triangle, a triangle, a square, a rectangle, a parallelogram, and a five sides. Shapes, hexagons, octagons, and the like. For example, FIGS. 9A and 9B illustrate a multi-component powder compacting die 200 including a circular mold cavity 210. The die 200 includes an orthogonal top section 230, an angled intermediate section 250, and an orthogonal bottom section 270. The orthogonal top section 230 includes a circular cavity formed by orthogonal cavity walls 235, the angled intermediate section 250 includes a circular cavity formed by the angled cavity walls 255 and the orthogonal bottom section 270 includes the orthogonal cavity walls A circular cavity formed by 275.

In various non-limiting embodiments, the mating surfaces of the plurality of segments including the multi-component powder compaction mold can include mutually contoured surfaces and/or other mutually matching alignment features to replace or supplement the alignment holes. 10A and 10B illustrate a multi-component powder compacting die 300 that includes an orthogonal top section 330, an angled intermediate section 350, and an orthogonal bottom section 370. The orthogonal top section 330 and the angled intermediate section 350 respectively include the mutually contoured bottom and top surfaces shown at 390. The mutually contoured bottom and top surfaces of the orthogonal top section 330 and the angled intermediate section 350 assist in stacking the stack of component sections to form the mold cavity 310, respectively. Although FIGS. 10A and 10B illustrate the mutually contoured surfaces shown at 390 other than the alignment holes 305, it should be understood that in various non-limiting embodiments, the mutually contoured surfaces and/or other mutually matching alignment features may be Use instead of aligning holes. In addition, although FIGS. 10A and 10B illustrate that the bottom surface and the top surface of the orthogonal top section 330 and the angled intermediate section 350 are mutually contoured surfaces, the top surface of the middle section and the top of the bottom section should be understood. The surfaces may also be contoured to one another and/or include alignment features that match each other.

In various non-limiting embodiments, the multi-element component powder compaction die can include a plurality of segments, such as, for example, two, three, four or more segments, which are configured to be together Assembled into alignment and stacking configurations and together form a cavity with sharp horizontal corner intersections and without the use of examples of the rounded corners, inconsistencies and shape deviations inherent in the monolithic powder compacting die made by the EDM. . 11A-11C illustrate a multi-component powder compaction mold including four aligned and stacked sections, and FIGS. 12A-12C illustrate a multi-component powder compaction mold including two aligned and stacked sections.

Referring to FIGS. 11A-11C, the multi-component powder compacting die 400 includes an orthogonal top section 430, an upper angled intermediate section 450a, a lower angled intermediate section 450b, and an orthogonal bottom section 470. The orthogonal top section 430 includes a generally square cavity formed by orthogonal cavities 435. The angular intermediate section 450a includes a generally square cavity formed by the upper angled cavity wall 455a, the lower angled intermediate section 450b includes a generally square cavity formed by the lower angled cavity wall 455b and the orthogonal bottom section 470 includes orthogonal The cavity wall 475 forms a generally square cavity. The multi-component powder compacting die 400 includes a mold cavity 410 formed by respective cavities of the stacking and alignment sections 430, 450a, 450b, and 470. The respective angles of the upper angled cavity wall 455a and the lower angled cavity wall 455b are different angles.

Referring to Figures 12A-12C, the multi-component powder compacting die 500 includes an angled top section 530 and an orthogonal bottom section 570. The angled top section 530 includes a generally square cavity formed by angled cavity walls 535 and the orthogonal bottom section 570 includes a generally square cavity formed by orthogonal cavity walls 575. The multi-component powder compacting die 500 includes a mold cavity 510 formed by respective cavities of the stacking and alignment sections 530 and 570. Although not shown, it should be understood that a multi-component powder compaction die comprising two component sections can include an orthogonal top section and an angled bottom section.

In various non-limiting embodiments, the multi-element powder compaction mold can include a plurality of mold cavities such as, for example, two, three, four or more cavities, etc. including sharp horizontal corner intersections In the case of the monolithic powder compacting die produced by the EDM, the rounding, inconsistency and shape deviation inherent in the monolithic powder compacting die are used. Referring to FIG. 13, the multi-element powder compacting die 600 includes an orthogonal top section 630, an angled intermediate section 650, and an orthogonal bottom section 670. Each of the orthogonal top section 630, the angled intermediate section 650, and the orthogonal bottom section 670 includes a plurality of chamber walls that form four generally square cavities. In the stacking and alignment configuration shown in Figure 13, the cavities of the respective sections form four mold cavities 610. Although four mold cavities are illustrated in Figure 12, it should be understood that the multi-element powder compaction mold can include any number of separate mold cavities.

In various non-limiting embodiments, a multi-component powder compacting die for making a cutting insert includes a plurality of die segments stacked and aligned to form a mold cavity. The mold cavity can include a sharp horizontal corner formed by the intersection of two flat cavity walls, wherein each flat cavity wall corresponds to one of a plurality of die segments. The flat cavity walls can have orthogonal orientations with respect to the top and/or bottom surfaces of the respective mold segments and/or relative to the top and/or bottom surfaces of the assembled mold or Angled orientation. The flat chamber walls may form cavities in the respective mold sections that together form a mold cavity when the respective mold sections are stacked and aligned for assembly configuration.

The respective mold segments can be fabricated by using linear material cutting techniques such as wire-cut EDM, laser cutting or water jet cutting in a cutting chamber in a workpiece. The respective mold segments can include any suitable material for use as a powder compaction mold, including but not limited to alloys such as tool steels and composites, such as cemented carbides. For example, in various non-limiting embodiments, the respective mold segments can include cobalt cemented tungsten carbide.

The respective mold sections can be joined together in a sequential stacking, alignment, and assembly configuration using mechanical fasteners, metallurgical joints, and/or adhesive joints. For example, any two or more of the mold segments can be welded together, brazed together, bonded together, clamped together, or otherwise mechanically fastened together. Accurate and precise positioning of the respective sections can be accomplished using alignment pins, dowels, rods or the like that are positioned to align with each other through the lockable sections of the mutually aligned apertures of the respective sections. Alternatively, mechanical fasteners, such as bolts, nuts, and the like, can be positioned to pass through mutually aligned apertures through the respective sections. It should be understood that two permanent joints, such as welds, welded joints and bonded joints (eg, heat-cured epoxy), and temporary joints, such as clamps and mechanical fasteners, can be used to join the respective mold sections together into an assembly configuration. .

In various non-limiting embodiments, the process of making a cutting insert includes pressing a metallurgical powder in a multi-component powder compacting die to form a powder compact. The multi-component powder compaction mold can be assembled from a plurality of respective mold segments stacked and aligned to form a mold cavity. Metallurgical powder can be introduced into the mold cavity. The upper press punch and the lower press punch can press and compact the metallurgical powder in the mold cavity to form a powder compact. The powder compact can be sintered to compact the compact and form a cutting insert. If desired, prior to sintering, the powder compact can be further shaped to produce desired geometric features such as chip breakers, grooves, facets on the blade face, the trailing edge face/gap face and/or the cutting edge prior to the cutting insert powder compact. And similar.

14A-14C illustrate the use of a multi-component powder compacting die 700 comprising orthogonal top segments, angled intermediate segments, and orthogonal bottom segments (similar to the multiple components shown in Figures 6A-6C) The powder compacting die 100 and the multi-component powder compacting die 200 shown in FIGS. 9A and 9B are used to produce a cutting insert powder compact 800/800'.

Metallurgical powder 750 is introduced into the mold cavity of multi-component powder compacting die 700. The core assembly 715 is positioned in the mold cavity to provide through holes 810/810' in the cutting insert powder compact 800/800'. The upper pressing punch 710 and the lower pressing punch 720 are vertically moved as indicated by arrows 711 and 721, respectively (Fig. 14A). The upper pressing punch 710 and the lower pressing punch 720 enter the multi-component powder compacting die 700 and compress the metallurgical powder in the cavity to form a powder compact 800/800' (Fig. 14B). The upper pressing punch 710 and the lower pressing punch 720 enter the multi-component powder compacting die 700 promoted by the orthogonal cavity walls of the orthogonal 700 section and the orthogonal bottom section of the die 700.

Figure 14C illustrates the cutting insert powder compact 800/800' in the cavity after the punches 710 and 720 are withdrawn from the mold cavity. The cutting insert powder compacts 800 and 800' are illustrated as being removed from the mold 700 in Figures 15A and 15B, respectively. The cutting insert powder compacts 800 and 800' have the shape and geometry of the mold cavity and include through holes 810 and 810' for attaching the resulting cutting insert to the cutting tool holder. The pressed compacts 800 and 800' can be sintered to densify the material and make a cutting insert.

The cutting insert powder compacting process illustrated in Figures 14A-14C can be modified to utilize any multi-component powder compacting die according to various non-limiting embodiments described herein. For example, Figure 16 illustrates a multi-element powder compacting die 900 comprising orthogonal top sections, two angled intermediate sections, and orthogonal bottom sections (similar to the multi-component powders shown in Figures 11A-11C) The compacting die 400) produces a cutting insert powder compact 1000/1000'.

The metallurgical powder is introduced into the cavity of the multi-component powder compacting die 900. The core assembly 915 is positioned in the mold cavity to provide a through hole 1100/1100' in the cutting insert powder compact 1000/1000'. The upper pressing punch 910 and the lower pressing punch 920 enter the multi-component powder compacting die 900 and compress the metallurgical powder in the cavity to form a powder compact. The upper pressing punch 910 and the lower pressing punch 920 enter the multi-component powder compacting die 900 promoted by the orthogonal cavity walls of the orthogonal top section and the orthogonal bottom section of the mold 900.

The cutting insert powder compacts 1000 and 1000' are illustrated as being removed from the mold 900 in Figures 17A and 17B, respectively. The cutting insert powder compacts 1000 and 1000' have the shape and geometry of the mold cavity and include through holes 1100/1100' for attaching the resulting cutting insert to the cutting tool holder. The pressed compacts 1000 and 1000' can be sintered to densify the material and make a cutting insert. Although not shown in FIGS. 14A to 17B, the geometry of the top surface and the bottom surface of the cutting insert powder compact produced in the multi-component powder compacting mold is respectively provided by the geometry of the pressed surface of the upper punch and the lower punch. .

This specification has been written with reference to various non-limiting and non-exhaustive embodiments. However, it will be apparent to those skilled in the art that various alternatives, modifications, or combinations of any of the disclosed embodiments (or portions thereof) can be made within the scope of the invention. Accordingly, it is contemplated and understood that this specification supports additional embodiments not explicitly stated herein. The various disclosed steps, components, components, features, aspects, characteristics, limitations, and combinations of the various non-limiting and non-exhaustive embodiments described in the specification are described herein. And analogs are obtained. In this manner, Applicants reserve the right to modify the scope of the patent application during the review to add features as described in this specification and such amendments are in accordance with 35 USC § 112, paragraph 1, and 35 USC § 132(a) .

100‧‧‧Multi-component powder compaction mould

105‧‧‧ Alignment holes

110‧‧‧ cavity

130‧‧‧Top section

131‧‧‧ top surface

150‧‧‧middle section

170‧‧‧ bottom section

173‧‧‧ bottom surface

Claims (33)

A multi-component powder compacting die for making a cutting insert, comprising: an orthogonal top section comprising an orthogonal cavity wall forming a top cavity in the orthogonal top section; at least one angled intermediate a section including an angled cavity wall forming at least one intermediate cavity in the angled intermediate section; and an orthogonal bottom section including forming a bottom cavity in the orthogonal bottom section a chamber wall; wherein the orthogonal top section, the at least one angled intermediate section, and the orthogonal bottom section are stacked and aligned such that the top cavity, the at least one intermediate cavity, and the bottom cavity together comprise one An orthogonal top chamber wall, at least one angled intermediate chamber wall, and a cavity of an orthogonal bottom chamber wall, the intersecting chamber walls forming a horizontal corner intersection in the mold cavity. The multi-component powder compacting mold of claim 1, wherein the mold comprises an angled intermediate section and the cavity comprises one of a horizontal corner intersecting the orthogonal top chamber wall and the orthogonal bottom chamber wall. Angle intermediate cavity wall. The multi-component powder compacting mold of claim 1, wherein the mold comprises an upper angled intermediate section and a lower angled intermediate section, and the cavity comprises an upper angled intermediate cavity wall and a lower angled intermediate cavity wall . The multi-component powder compacting mold of claim 3, wherein the upper angled intermediate cavity wall forms a horizontal corner intersection with the orthogonal top cavity wall, and wherein the lower angled intermediate cavity wall and the orthogonal bottom cavity The wall forms a horizontal corner intersection. The multi-component powder compacting mold of claim 1, wherein the cavity comprises a group selected from the group consisting of a circle, a triangle, a triangle, a square, a rectangle, a parallelogram, a pentagon, a hexagon, and an octagon. A peripheral shape. A multi-component powder compacting mold according to claim 1, wherein the mold cavity comprises a substantially square peripheral shape. The multi-component powder compacting mold of claim 1, wherein the mold cavity comprises a substantially circular peripheral shape. A multi-component powder compaction mold of claim 1, wherein at least two of the orthogonal top section, the at least one angled intermediate section, and the orthogonal bottom section comprise mutually contoured surfaces. The multi-component powder compaction mold of claim 1, wherein the orthogonal top section, the at least one angled intermediate section, and the orthogonal bottom section comprise configured to receive an alignment pin to lock the zone The segments are aligned holes that are aligned with each other. The multi-component powder compaction mold of claim 1, wherein the orthogonal top section, the at least one angled intermediate section, and the orthogonal bottom section are stacked, aligned, and permanently joined together. The multi-component powder compacting mold of claim 10, wherein the orthogonal top section, the at least one angled intermediate section, and the orthogonal bottom section are adhesively joined together. The multi-component powder compacting mold of claim 10, wherein the orthogonal top section, the at least one angled intermediate section, and the orthogonal bottom section are metallurgically joined together. The multi-component powder compacting mold of claim 1, wherein the orthogonal top section, the at least one angled intermediate section, and the orthogonal bottom section are mechanically fastened together. The multi-component powder compaction mold of claim 1, wherein the orthogonal top section, the at least one angled intermediate section, and the orthogonal bottom section are formed from a material comprising an alloy. The multi-component powder compaction mold of claim 1, wherein the orthogonal top section, the at least one angled intermediate section, and the orthogonal bottom section are formed from a material comprising cemented carbide. A multi-component powder compacting die for making a cutting insert, comprising: a top section comprising a cavity wall forming a top cavity in the top section; And a bottom section comprising a cavity wall forming a bottom cavity in the bottom section; wherein the top section and the bottom section are stacked and aligned such that the top cavity and the bottom cavity together form a top portion a cavity of the cavity wall and a bottom cavity wall. The multi-component powder compacting mold of claim 16, further comprising an angled intermediate section, wherein the mold cavity includes an intermediate chamber wall at an angle to one of a horizontal corner of the top chamber wall and the bottom chamber wall . The multi-component powder compacting mold of claim 16, further comprising an upper angled intermediate section and a lower angled intermediate section, wherein the cavity comprises an upper angled intermediate cavity wall and a lower angled intermediate cavity wall, Wherein the upper angled intermediate chamber wall forms a horizontal corner intersection with the top chamber wall, and wherein the lower angled intermediate chamber wall forms a horizontal corner intersection with the bottom chamber wall. The multi-component powder compacting mold of claim 16, wherein the top chamber wall and the bottom chamber wall are orthogonal to the chamber wall. The multi-component powder compacting mold of claim 16, wherein the mold cavity comprises a group selected from the group consisting of a circle, a triangle, a triangle, a square, a rectangle, a parallelogram, a pentagon, a hexagon, and an octagon. A peripheral shape. The multi-component powder compaction mold of claim 16, wherein the top section and the bottom section comprise alignment holes configured to receive an alignment pin to lock the sections to be aligned with one another. The multi-component powder compacting mold of claim 16, wherein the top section and the bottom section are stacked, aligned and bonded together. The multi-component powder compacting mold of claim 16, wherein the top section and the bottom section are stacked, aligned and metallurgically bonded together. The multi-component powder compacting mold of claim 16, wherein the top section and the bottom section are stacked, aligned and mechanically fastened together. The multi-component powder compacting mold of claim 16, wherein the top section and the bottom section are formed from a material comprising an alloy. The multi-component powder compaction mold of claim 16, wherein the top section and the bottom section are formed from a material comprising cemented carbide. A process for making a cutting insert, the process comprising: introducing a metallurgical powder into the cavity of the multi-component powder compacting mold of claim 1; pressing the punch in the cavity with a pressing punch entering the cavity a metallurgical powder to compress the metallurgical powder and form a powder compact; remove the powder compact from the mold cavity; and sinter the powder compact. A process for making a multi-component powder compacting die, the process comprising: cutting a workpiece using a linear material cutting technique to form an orthogonal top section, the orthogonal top section being included in the orthogonal top section Forming an orthogonal cavity wall in one of the top chambers; cutting a workpiece using a linear material cutting technique to form an angled intermediate section comprising at least one intermediate portion formed in an angled intermediate section One of the cavities is angled to the cavity wall; a workpiece is cut using a linear material cutting technique to form an orthogonal bottom section comprising an orthogonal cavity forming a bottom cavity in an orthogonal bottom section a wall; stacking the orthogonal top section, the angled intermediate section, and the orthogonal bottom section; aligning the orthogonal top section, the angled intermediate section, and the orthogonal bottom section such that the top The cavity, the at least one intermediate cavity and the bottom cavity together form a cavity including an orthogonal top cavity wall, an angled intermediate cavity wall and an orthogonal bottom cavity wall, the cavity walls forming a level in the cavity Corner intersection; and The orthogonal top section, the angled intermediate section, and the orthogonal bottom section are joined. The process of claim 28, wherein the linear material cutting technique comprises wire cut electrical discharge machining. The process of claim 28, further comprising cutting the alignment holes in the workpieces, and wherein aligning the orthogonal top segments, the angled intermediate segments, and the orthogonal bottom segments comprises placing an alignment pin Positioned in the alignment holes, thereby locking the segments into mutual alignment. The process of claim 28, wherein joining the orthogonal top section, the angled intermediate section, and the orthogonal bottom section comprises bonding the sections together. The process of claim 28, wherein joining the orthogonal top section, the angled intermediate section, and the orthogonal bottom section comprises metallurgically joining the sections together. The process of claim 28, wherein joining the orthogonal top section, the angled intermediate section, and the orthogonal bottom section comprises mechanically fastening the sections together.